This present study employs aluminum substrates to investigate the formation of Cr(VI) species during a trivalent chromium conversion coating process. The study had a particular focus on understanding the influences of copper in the substrate and O 2 , ZrF 6 2− and F − in the bath on the formation of Cr(VI) species, which were detected by Raman spectroscopy. Comparison of electropolished aluminum and sputtering-deposited aluminum substrates revealed greatly increased rates of coating growth associated with an enrichment of copper impurity in the electropolished substrate that was revealed by transmission electron microscopy. With respect to chromium chemistry in a developed coating, the presence of dissolved oxygen and long conversion treatment times promoted the formation of Cr(VI) species that are generated by oxidation of Cr(III) species. The Cr(III) species are oxidized by H 2 O 2 , which was produced by oxygen reduction reaction. The generation of H 2 O 2 was demonstrated by analysis of the treatment bath using UV spectrophotometry. Conversion coating processes are employed as surface pretreatments of aluminum and aluminum alloys to improve the adhesion with organic primers and increase corrosion protection. Chromate conversion coating (CCC) has been widely used as a conventional and effective process in the aerospace and automotive industries.1-3 However, the toxicity of chromates to human beings and the detrimental impact of chromates on the environment are giving rise to greater regulation of their use. 4,5 In contrast, trivalent chromium species are relatively eco-friendly and, hence, trivalent chromium conversion (TCC) coating processes are being investigated as promising alternatives to CCC processes.
6The TCC coating bath generally contains hexafluorozirconate, sodium fluoride and trivalent chromium sulfate, which results in coatings formed on aluminum that contain Zr-/Cr-rich oxides, hydroxides and fluorides.6-8 Interestingly, a freshly-formed TCC coating after a conversion treatment for 1200 s in a naturally-aerated bath displayed chromate presence by a Raman shift at 866 cm −1 , but the peak intensity was negligible in a coating formed in a deoxygenated bath. 8 Notably, the oxidation of Cr 3+ to Cr 6+ in the aqueous electrolyte is not due solely to the presence of dissolved oxygen. This conclusion is supported by experiments in which no significant chromate species were found in the solution bubbled with only air for more than 300 h. 9 In contrast, the Cr 3+ /Cr 6+ reaction has been reported to occur in atmospheric oxygen at high temperature during a bush fire 10 and also with the presence of MnO 2 oxidant in the natural sea water. 11,12 In the case of TCC coatings, chromate formation has been attributed to the transient formation of hydrogen peroxide generated by oxygen reduction. The influence of H 2 O 2 has been explored by Li et al.,13 who immersed TCC coated AA2024 alloy in 0.5 M Na 2 SO 4 solutions with addition of 0.01, 0.1 and 1 v/v % H 2 O 2 for 1 h. A small level (0.01% v/v) of H 2 O 2 ca...